Insulation barrier and a method of making an insulation barrier

Abstract

The insulation barrier is formed of a body of foamed polystyrene, either expanded or extruded, which is provided with a protective coating formed of a metallic-based inorganic material and is applied over at least one surface of the body. Optionally, a fire resistant composition of any inorganic silicate, boric acid, any salts of boric acid, hydrated sodium borate (borax) or mixtures thereof, and preferably sodium silicate, is applied in solution form and maintained within the body by a wetting agent in the solution. The protective coating is being applied by a coating roller followed drying of the polystyrene body.

What is claimed is: 
     
       1. An insulation system comprising: a. a body of foamed polystyrene having a plurality of closed cells therein, and further having a bottom surface for laying on a substrate and an upper surface; and   b. a protective coating on at least said bottom surface of said body including a metallic-based inorganic material selected from the group consisting of aluminum oxide trihydrate, hydrated boron oxide, antimony oxide, titanium dioxide, magnesium hydroxide and mixtures of at least two of said materials.   
     
     
       2. An insulation system as set forth in claim 1, wherein said protective coating includes an organic emulsion. 
     
     
       3. An insulation system as set forth in claim 2, wherein said protective coating is made of aluminum oxide trihydrate and latex. 
     
     
       4. An insulation system as set forth in claim 2, wherein said organic emulsion is comprised of vinyl acetate, ethylene and vinyl chloride polymer. 
     
     
       5. An insulation system as set forth in claim 1, wherein said foamed polystyrene is selected from the group consisting of expanded and extruded polystyrene. 
     
     
       6. An insulation system as set forth in claim 1, wherein a fire resistant composition is impregnated into said body. 
     
     
       7. An insulation system as set forth in claim 6, wherein said fire resistant composition is selected from the group consisting of any inorganic silicate, boric acid, any salt of boric acid, hydrated sodium borate and mixtures thereof. 
     
     
       8. In combination, a. a steel roof deck; and   b. an insulating layer on said deck, said insulating layer being made of foamed polystyrene and having a coating of a metallic-based inorganic material on at least a bottom surface thereof facing said steel roof deck,   wherein said metallic-based inorganic material is selected from the group consisting of aluminum oxide trihydrate, hydrated boron oxide, antimony oxide, titanium dioxide, magnesium hydroxide and mixtures of at least two of said materials.   
     
     
       9. The combination as set forth in claim 8 which further comprises a barrier sheet over said insulating layer and a roof membrane over said sheet. 
     
     
       10. The combination as set forth in claim 8 which further comprises a roof membrane over said layer and ballast over said membrane. 
     
     
       11. The combination as set forth in claim 8 which further comprises a rigid overlayment over said layer and built up roofing over said rigid overlayment.